Introduction: Simple Band Saw Circle Cut Gigue

A circle cutting jig is something I have needed for some projects over the years. The problem is you take one merely you'Ra in the middle of another more galvanising project. In the past I've old something that works only isn't easy to use or setup.

This quick project leave defecate lancinate circles of any size on the band saw quick and comfortable to setup for all future projects.

Footstep 1: Tools and Materials

Materials:

  • 1/2 in. Plywood
  • 1/4 in. T-Nut
  • 1/4 in. Machine Screw
  • 5/16 in. T-Nut
  • 5/16 in. Baby buggy Gobble
  • 5/16 in. Washer
  • Chip Hardwood
  • Double Sided Tape
  • Screws
  • Water Based Polyurethane
  • Wood Glue

Tools:

  • Bandsaw
  • Bench Grinder
  • Nail Gun
  • Table Saw
  • Squared
  • Router
  • Sander
  • Swath Sander
  • Disc Sander
  • Forstner Bits

Step 2: Make Base of Jig

Cut two equal squares of plywood (mine are 16 x 16 in.). I elect two squares that are larger than the table of my bandsaw and could be taken from a scrap piece of wood I had in the snitch.

Mucilage and complete a piece of hardwood to play the stay for your jig. This firearm of wood will bump high against the front of the table on the band saw. Make true the stop is short enough that it doesn't run into any hardware or other irregular shapes on the front of your table (my stop measures 10 x 1/2 x 3/4 in.).

Step 3: First Cut

Using a palisade (or straight board to act as a fence), prepar the first dig in the bottom board with the stop in situ. I left 4 in. to the far left of the blade to play support for cutoff corporeal.

Step 4: Runner

Using the table adage, cut a runner just shallower than the track of your table. Take small cuts off until it's just the right size of it. If you cut it too immature (like I did), you can save it by cutting some reliefs in each finish so manipulation small screws to expand the ends of the runner.

Place close to washers under the runner to elevate it above the come up of the table. Implement 2 sided tape along the runner and slide the jig in place and press down. Remove the fence and slide the jig off the remit and attach the runner with screws.

Impound the second square of plywood to the top of the base square with a lot of screws (I ended up adding more in a future step).

Step 5: Severed Slot

Using a square, transfer the max depth of trim to the left hand side of the jig. Measuring an inch to either side of the center mark testament indicate where to cut the 45 degree tracks.

Transfer the upper side feather and cut both 45 degree angles on the table saw.

Measure 6: Reattach Top

Reattach peak and secure with more screws as needed.

Step 7: Pierced Slide

Using another scrap piece of plywood (17 in. long), cut 45 point angles until it fits. You can make over quaternary lengths of this slide for different groups of circle sizes.

For case, this slideway can cut circles with diameters ranging in 2-18 in, and 33-50 in. (by flipping the slideway around). I will need to make another microscope slide in the early if I ever so want to cut a rophy with diameters in range from 18 and 33 in.

Step 8: Path Slots

Using a router, cut a 5/16 in. slot starting 1 in. from peerless end and ending 2 in. from the other. Cut a 3/4 in. expansion slot 3/16 late on the narrower top of the slide.

Drill a 1/4 in. through jam 1 in. from the end and cant the bottom of the hole so the flat head screw is flush against the fathom.

Using a 7/8 in. forstner bit, drill a recess for the t-nut. Tap the t-nut in place to mark the location of the four tines. Remove the t-nut and practise small reliefs at those 4 locations.

Tighten pull down the flat head screw to secure the t-nut in place.

Note: I did not take aim pictures of grinding down the tip of the flat head screw. This was done victimization a bench grinder.

Step 9: Secure Slide

Insert the slide back in the slot and mark the localisation to drill a headway hole for the carriage bolt.

Step 10: Build Star Knob

Photographic print off the attached star knob template at 143% to birth the 2 1/2 in. maven knob sized that I utilised.

You can actually use this expression along with the attached guide to calculate what portion to print the templet off at to get your desired size of star knob:

Apply the template using spray adhesive. Serrulate cut the conformation along the bandsaw and smooth human body using a strip sander and disc electric sander.

Drill a 1 in. recess to allow for the thickness of the t-nut. Drill a 3/8 in. headway hole through the star thickening.

Using the same technique Eastern Samoa before, mark and practice session relief holes for the 4 tines of the t-nut.

Secure the t-fruitcake in place using half-size wood screws at an fish.

Gluing along a fine piece of walnut is optional but I think information technology ads a shrimpy something that no one will of all time see.

Step 11: Apply Finish

Sand everything up to 200 grit and apply 2-3 coats of water based polyurethane to help protect the wood.

Step 12: Cut Circles

To cut a circle, set the point on the lantern slide to the spoke of the desired traffic circle. Measure from the side of the band saw blade to the center of the pointedness. Tighten star node to hold glide in place. Mark the center of the circle connected your Grant Wood and drill a small hole the size of the point of the center of the slide. Slide the wood on the point of the gigue while the jig is not attached to the striation saw. Twist on the saw and slide the jig into place. Lento plow the wood to cut the circle. In one case the circle is cut entirely, put off the band byword and remove the circle and scrap from the jig and power saw.

Be the First to Share

Recommendations